Processed cauliflower and cauliflower processing method

ABSTRACT

A processed cauliflower mixture includes a plurality of cauliflower stem pieces cut from a cauliflower stem, a plurality of cauliflower crown pieces cut from a cauliflower crown, and packaging containing a mixture of the plurality of cauliflower stem pieces and the plurality of cauliflower crown pieces. The cauliflower stem is treated, prior to being cut into the plurality of cauliflower stem pieces, such that the cauliflower stem mimics the visual and tactile effects of the cauliflower crown.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is based on and claims priority to U.S. patentapplication Ser. No. 14/938,557, filed on Nov. 11, 2015, which claimspriority to U.S. Provisional Patent Application No. 62/152,867, filed onApr. 25, 2015, the entire contents of each of which are herebyincorporated by reference herein.

BACKGROUND

1. Field of the Disclosure

The present disclosure describes processed cauliflower and methods ofprocessing cauliflower.

2. Description of the Related Art

Raw prepared cauliflower packaged sales are currently estimated to beover $200 million dollars per year with a loss of 21% to the consumerdue to cauliflower stem rejection, representing approximately $43million in losses for consumers due to looks rather than due tofunction, nutrition or organoleptic properties. There is a need toimprove upon the related art in the field of processing and packaging ofraw vegetables, including cauliflower.

SUMMARY

The present disclosure is directed to a method for processingcauliflower, the method comprising pre-washing a cauliflower, includingremoving unwanted dust, residual, and debris from the cauliflower;washing the cauliflower with a wash solution containing at least one ofsodium hypochlorite, calcium hypochlorite, organic acids, chlorinedioxide, silver ion, water treated with ozone, water treated with pulsedelectric field, and water treated with ultraviolet radiation; andpulverizing the cauliflower, including at least one of the steps ofsizing, grinding, sanding, and crushing the cauliflower;

The foregoing general description of the illustrative implementationsand the following detailed description thereof are merely exemplaryaspects of the teachings of this disclosure, and are not restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the disclosure and many of the attendantadvantages thereof will be readily obtained as the same becomes betterunderstood by reference to the following detailed description whenconsidered in connection with the accompanying drawings wherein:

FIGS. 1A and 1B are drawings of a head of cauliflower;

FIG. 2A is a diagram representing a sequence of primary processes of acauliflower processing method;

FIG. 2B is a diagram representing a sequence of primary processes of acauliflower processing method;

FIG. 2C is a diagram representing a sequence of primary processes of acauliflower processing method;

FIG. 3 is a perspective view of a plastic container;

FIG. 4A is a plan view of a portion of a film seal;

FIG. 4B is a side view of a rigid plastic container;

FIG. 4C is a plan view of a portion of a rigid plastic lid; and

FIG. 4D is a side view of a rigid plastic container.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In the drawings, like reference numerals designate identical orcorresponding parts throughout the several views. Further, as usedherein, the words “a”, “an” and the like generally carry a meaning of“one or more”, unless stated otherwise.

Referring now to the drawings, wherein like reference numerals designateidentical or corresponding parts throughout the several views.

FIGS. 1A and 1B are drawings of a cauliflower 1, including a crownportion 2 connected to a cauliflower stem 4. Further, all references tothe cauliflower 1 below include a pulverized cauliflower 8 form (FIG.1B). As noted above, considerable loss is incurred when the consumerrejects the cauliflower stem 4. Accordingly, the processes describedbelow aim to minimize this loss by processing the cauliflower stem 4along with the crown portion 2 such that the processed cauliflower stem4 resembles the processed crown portion 2. For example, the processedcauliflower stem 4 resembles the crown portion 2 in one or more oftexture, size, visual appearance, color, density, and how the processedcauliflower stem 4 and the processed crown portion 2 are blended,mashed, or otherwise physically incorporated into one another as a foodingredient. Thus, the processed cauliflower stem 4 and the processedcauliflower crown 2 are indistinguishable in appearance and consistentin the way they blend, mash, cook, taste, appear and otherwise perform,thereby resulting in less waste, less preparation time, and savings tothe consumer, the producer, and the environment.

FIG. 2A is a diagram representing a sequence of primary processes of acauliflower processing method 6A. The cauliflower processing method 6Aincludes a pre-washing process S200, a washing process S400, a reshapingprocess S500, a pulverizing process S600, a sizing process S300, apost-washing process S700, and a packaging process S800.

S200 represents a process of pre-washing the cauliflower 1, which mayinclude steps related to removing unwanted dust, residual, debris andquality defects. Further, the process may include application ofwhiteners, anti-microbial rinses and coatings to enhance appearanceand/or shelf life, application of physical coating(s) to adhere othermaterials such as cheese, oils, vinegar, malt, flavorings, extracts,essences and preservatives to the cauliflower 1 and/or steps forslicing, cutting, chopping, and dicing of the cauliflower 1, which mayinclude at least one of sizing, grinding, sanding, and crushing steps.

S400 represents a process of washing, sanitizing and/or further removingdebris from the cauliflower 1 (collectively, “washing”). S400 mayinclude washing the cauliflower 1 in a chlorinated wash solution withproprietary silicate treatment (“wash solution”), whereby the washsolution applied to the cauliflower 1 using one of a number of washingmethods, including without limitation, a belt and spray mechanism or aflume-type, tube-type or other bathing, submersion or rinsing mechanism.S400 may also include application of whiteners, anti-microbial rinsesand coatings to enhance appearance and/or shelf life, and/or applicationof physical coating(s) to adhere other materials to the cauliflower 1such as cheese, oils, vinegar, malt, flavorings, extracts, essences andpreservatives.

In another example, the cauliflower 1 is washed using a wash solutioncontaining sodium hypochlorite.

In another example, the cauliflower 1 is washed using a wash solutioncontaining calcium hypochlorite.

In another example, the cauliflower 1 is washed using a wash solutioncontaining organic acids.

In another example, the cauliflower 1 is washed using a wash solutioncontaining chlorine dioxide.

In another example, the cauliflower 1 is washed using a wash solutioncontaining silver ion.

In another example, the cauliflower 1 is washed using water treated withozone.

In another example, cauliflower 1 is washed using water treated withpulsed electric or magnetic field.

In another example, the cauliflower 1 is washed using water treated withultraviolet radiation.

S500 represents a process of reshaping the cauliflower 1. Reshaping maybe performed, depending on limitations present in the machinery used inthe cauliflower processing method 6A, and includes halving, quarteringor otherwise reshaping the cauliflower 1.

In another example the reshaping process S500 is not included in thecauliflower processing method 6A.

S600 represents the process of pulverizing cauliflower 1 such that thecauliflower stem 4 and crown portion 2 are broken down into the desiredsize pieces. In one example, the cauliflower 1 is pulverized to pieceshaving a volume of 1500 mm³ or less. The pulverizing process may includeat least one of grinding, cutting, slicing, chopping, dicing, sanding,and crushing of the cauliflower.

S600 may also include application of whiteners, anti-microbial rinsesand coatings to enhance appearance and/or shelf life, and/or applicationof physical coating(s) to adhere other materials to the cauliflower 1being pulverized such as cheese, oils, vinegar, malt, flavorings,extracts, essences and preservatives.

In one example, the pulverizing process includes the use of rotaryhammer and anvil to crush the cauliflower 1 into proper sizes, shapes,visual and tactile appearance.

In another example, the pulverizing process includes the use of ceramicsanding balls to sand the outer skin of the cauliflower 1 into propersizes, shapes, visual and tactile appearance.

In another example, the pulverizing process includes the use of aceramic grinding stone to grind the outer skin of the cauliflower 1 intoproper sizes, shapes, visual and tactile appearance.

In another example, the pulverizing process includes the use of highpressure water jets to score and break the cauliflower 1 into propersizes, shapes, visual and tactile appearance.

In another example the pulverizing process includes a hydraulicfracturing process composed of a high pressure step then aninstantaneous vacuum step leading to a popcorn effect on the whole ofthe cauliflower 1 to improve the visual and tactile appearance.

As a result of pulverizing, the cauliflower 1 is broken down into pieceshaving a size of approximately a maximum 1500 mm³ to approximately aminimum of 15 mm³.

In another example, the pulverizing cauliflower 1 is broken down intopieces having a size of approximately 250 mm³ plus or minus 50 percent.The pulverizing process S600 can also include a spice admix step toembody the spices into the outer skin of the cauliflower 1 prior to postwashing using vacuum or other methods of infusion.

The pulverizing process S600 can also include a physical coating step toadhere other materials such as cheese, oils, vinegar, malt, flavorings,extracts, essences and preservatives into the outer skin of thecauliflower 1 prior to post washing.

Additionally, prior to the pulverizing process S600 or as part of thepulverizing process S600, the processing method 6A may include a markingstep to notch the smooth ends and sides of the cauliflower 1 usingmethods including without limitation, texture mats, cutting blades orinstruments, pressure rolling or stamping, sanding, grinding, or highpressure water of the cauliflower stem 4 to mimic the visual and tactileeffects of the crown portion 2 of the cauliflower 1 prior to entering atleast one of a grinding, sanding, or crushing step of the pulverizingprocess S600.

S300 represents an optional process for sizing the cauliflower 1. Thesizing process S300 is optional and, in certain embodiments, the othersteps of the processing method 6A depicted in FIG. 2A are performedwithout the sizing process S300. The sizing process includes gauging thecauliflower 1 through at least one of the steps of using a screen,rotary screen, vibratory screen, 15 camera visual inspection, andautomatically through robotic feeler gauges to ascertain the dimensionsof the cauliflower 1. Further, the sizing process S300 may be performedat any point in the process of method 6A prior to packaging. In thisexample, it occurs after the pulverization process S600. In anotherexample, the sizing process S300 may be performed prior to the washingprocess S400.

S700 represents a process of post-washing, sanitization, coating and/ortreatment (collectively, “post-washing” or “post wash”) of thecauliflower 1 to increase the brightness, enhance shelf life and foodsafety, and regulate, maintain or otherwise optimize moisture content ofthe cauliflower 1. In one embodiment there may include a post-washingprocess to remove unwanted small particles of the cauliflower 1 andprovide antimicrobial treatment.

For example, one example of a post-washing step includes washing thepulverized cauliflower 8 with a wash that contains antimicrobials,preservatives and whiteners to maintain and possibly increase thebrightness, moisture content, food safety, shelf life and preservationof the cauliflower 1.

In another example, the post-washing process may include a chemicalcoating step to improve and increase shelf life and maintain moisturecontent of the cauliflower 1.

In another example, the post-washing process may include a vacuumcooling step to aid in cooling and drying of the surface the cauliflower1.

In another example, the post-washing process may include a centrifugaldrying step to eliminate unwanted moisture on the surface of thecauliflower 1 produced during the pre-washing and post-washing steps.

In another example, the post-washing process may include a physicalcoating step to adhere other materials such as cheese, oils, vinegar,malt, extracts, essences, flavorings and preservatives.

In another example, the post-washing process may include a physicalcoating step to adhere other materials such as vitamins and minerals.

In another example, the post-washing process may include a physicalcoating step to adhere other materials such as spice admix.

Further, more than one of the above post-washings steps may be combinedas part of the process of post-washing S700.

S800 represents a process of packaging the cauliflower 1. In oneembodiment, the pulverized cauliflower 8 is injected into a plasticcontainer 10 (see FIG. 3) comprising laminated layers of material suchas polyethylene, coextruded polypropylene, and adhesive, whereupon theplastic container 10 is sealed. The plastic container 10 is engineeredto meet the respiration requirements of the pulverized cauliflower 8contained therein. This can be accomplished using one or more of theperforation methods described below. The plastic container 10 isequipped with venting technology allowing steam to release at prescribedtemperatures, permitting microwave cooking resulting in a consistentend-product with minimal consumer preparation.

In another example, the pulverized cauliflower 8 is injected into aplastic container 10, the plastic container 10 comprising a monolayer(non-laminated) of polyethylene film.

In another example, the pulverized cauliflower 8 is injected into arigid plastic container 16, whereupon a film seal 18 (see FIG. 4A andFIG. 4B) or a rigid plastic lid 26 (see FIG. 4C and FIG. 4D) is appliedto create a modified internal atmosphere.

In another example, a plurality of perforations 20 is located on thefilm seal 18 or on the rigid plastic lid 26 applied to the rigid plasticcontainer 16. The plurality of perforations 20 may also be distributedon the rigid plastic container 16. The plurality of perforations 20 maybe formed, for example, using laser.

In another example, the plurality of perforations 20 described above maybe located near the top, middle, and bottom of the plastic container 10,either on a first surface, a second surface or a combination of thefirst surface and the second surface. Further, the plastic container 10may be of a laminated or non-laminated construction.

In another example, the plurality of perforations 20 described above aredistributed throughout the top and bottom of the plastic container 10evenly so as to prevent creation of microatmospheres in the plasticcontainer 10.

In another example, the plurality of perforations 20 described below aredistributed in a two thirds (⅔) ratio towards the bottom half of theplastic container 10.

FIG. 2B is a diagram representing another exemplary embodiment of asequence of primary processes of a cauliflower processing method 6B. Theprimary processes of method 6B are similar to those described withreference to FIG. 2A. However, the sequence of the primary processesdiffers from the sequence of FIG. 2A. In the embodiment of FIG. 2B, thesequence of primary processes of the cauliflower processing method 6Bincludes the pre-washing process

S200, the washing process S400, the pulverizing process S600, and thepackaging process S800.

In another example, the sizing process S300 (described by FIG. 2A) maybe performed after the pulverizing process S600, prior to the packagingprocess S800.

FIG. 2C is a diagram representing another exemplary embodiment of asequence of primary processes of a cauliflower processing method 6C. Theprimary processes of method 6C are similar to those described withreference to FIG. 2A and FIG. 2B. However, the sequence of the primaryprocesses differs from the sequences of FIG. 2A and FIG. 2B. In theembodiment of FIG. 2C, the sequence of primary processes of thecauliflower processing method 6C includes the pre-washing process S200,the washing process S400, the pulverizing process S600, and the 20post-washing process S700.

FIG. 3 is a perspective view of the plastic container 10. In thisembodiment the plastic container 10 is a sealed bag having the pluralityof perforations 20. As mentioned above, the plurality of perforationsmay be distributed on the first surface or the second surface toward thetop, middle, or bottom. Further, the plurality of perforations 20 may bedistributed evenly on the first and second surfaces of the plasticcontainer 10, or the plurality of perforations 20 may be distributedwith a portion of the plurality of perforations 20 concentrated toward aparticular portion of the plastic container 10, for example, with abouttwo thirds (⅔) of the perforations located on the bottom half of theplastic container 10.

FIG. 4A is a plan view of a portion of the film seal 18. In thisembodiment the film seal 18 has the plurality of perforations 20disposed on its surface.

FIG. 4B is a side view of the rigid plastic container 16. In thisembodiment the film seal 18 is disposed above the rigid plasticcontainer 16, and the film seal 18 is connected around the top perimeterof the rigid plastic container 16, sealing the contents of the rigidplastic container 16.

FIG. 4C is a plan view of a portion of the rigid plastic lid 26. In thisembodiment the rigid plastic lid 26 has the plurality of perforations 20disposed on its surface.

FIG. 4D is a side view of the rigid plastic container 16. In thisembodiment the rigid plastic lid 26 is disposed above the rigid plasticcontainer 16, the rigid plastic lid 26 and the rigid plastic container16 are connected around the top perimeter of the rigid plastic container16, sealing the contents of the rigid plastic container 16.

Thus, the foregoing discussion discloses and describes merely exemplaryembodiments of the present invention. As will be understood by thoseskilled in the art, the present invention may be embodied in otherspecific forms without departing from the spirit or essentialcharacteristics thereof. Accordingly, the disclosure of the presentinvention is intended to be illustrative, but not limiting of the scopeof the invention, as well as other claims. The disclosure, including anyreadily discernable variants of the teachings herein, defines, in part,the scope of the foregoing claim terminology such that no inventivesubject matter is dedicated to the public.

What is claimed is:
 1. A processed cauliflower mixture, the mixturecomprising: a plurality of cauliflower stem pieces cut from acauliflower stem; a plurality of cauliflower crown pieces cut from acauliflower crown; and packaging containing a mixture of the pluralityof cauliflower stem pieces and the plurality of cauliflower crownpieces, wherein the cauliflower stem is treated, prior to being cut intothe plurality of cauliflower stem pieces, such that the cauliflower stemmimics the visual and tactile effects of the cauliflower crown.
 2. Theprocessed cauliflower mixture of claim 1 wherein: the plurality ofcauliflower stem pieces and the plurality of cauliflower crown piecesare sealed within the packaging and are indistinguishable in visualappearance.
 3. The processed cauliflower mixture of claim 1 wherein: ahydraulic fracturing pressure and an instantaneous vacuum pressure havebeen applied to both the plurality of cauliflower stem pieces and theplurality of cauliflower crown pieces.
 4. The processed cauliflowermixture of claim 1 wherein: the plurality of cauliflower stem pieces andthe plurality of cauliflower crown pieces are each sized to betweenapproximately 15 mm³ and 1500 mm³.
 5. The processed cauliflower mixtureof claim 1 wherein: the plurality of cauliflower stem pieces and theplurality of cauliflower crown pieces are each sized to approximately250 mm³ with a tolerance of 50 percent.
 6. The processed cauliflowermixture of claim 1 wherein: the packaging includes a plurality ofperforations.
 7. The processed cauliflower mixture of claim 1 wherein:the plurality of cauliflower stem pieces and the plurality ofcauliflower crown pieces are sealed within the packaging via a film onthe packaging.
 8. The process cauliflower mixture of claim 1 wherein: atleast a portion of the plurality of cauliflower stem pieces and theplurality of cauliflower crown pieces are coated with at least one of aspice admix, a cheese, an oil, a vinegar, a malt, a flavoring, apreservative, and a vitamin and mineral admix.
 9. The processcauliflower mixture of claim 1 wherein: at least a portion of thecauliflower stem and the cauliflower crown are treated with a substanceincluding at least one of an antimicrobial, a preservative, a whitener,and a chemical coating.
 10. The process cauliflower mixture of claim 1wherein: at least a portion of the cauliflower stem and the cauliflowercrown are washed with a wash solution containing at least one of sodiumhypochlorite, calcium hypochlorite, organic acids, chlorine dioxide,silver ion, water treated with ozone, water treated with pulsed electricfield, and water treated with ultraviolet radiation.
 11. A method forprocessing cauliflower, the method comprising: washing at least aportion of cauliflower that includes a stem portion and a crown portion;sizing at least the portion of the cauliflower, including at least oneof the steps of grinding, sanding, crushing, cutting, scoring andbreaking, and hydraulically fracturing and instantaneously vacuum dryingthe stem portion of the cauliflower and the crown portion of thecauliflower, wherein the sizing is performed on both the stem portion ofthe cauliflower and the crown portion of the cauliflower; and packagingthe cauliflower comprising the stem portion and the crown portion of thecauliflower together in a container; wherein the sizing treats thecauliflower stem so that the stem mimics the visual and tactile effectsof the crown portion prior to processing, and the stem and the crownportions in the container are indistinguishable in visual appearance.12. The method of claim 11, wherein: the washing includes removingunwanted dust, residual, and debris from the portion of the cauliflower.13. The method of claim 11, wherein: the washing includes washing theportion of the cauliflower a wash solution containing at least one ofsodium hypochlorite, calcium hypochlorite, organic acids, chlorinedioxide, silver ion, water treated with ozone, water treated with pulsedelectric field, and water treated with ultraviolet radiation.
 14. Themethod of claim 11, further comprising: gauging the portion of thecauliflower with at least one of a screen, a camera, visual inspection,and automatic robotic feeler gauges.
 15. The method of claim 11,wherein: the washing includes at least one of applying whiteners andapplying rinses and coatings to at least the portion of the cauliflower.16. The method of claim 11, wherein: the sizing includes at least one ofmarking and notching at least the portion of the cauliflower.
 17. Themethod of claim 11 wherein: the plurality of cauliflower stem pieces andthe plurality of cauliflower crown pieces are each sized to betweenapproximately 15 mm³ and 1500 mm³.
 18. The method of claim 11 wherein:the plurality of cauliflower stem pieces and the plurality ofcauliflower crown pieces are each sized to approximately 250 mm³ with atolerance of 50 percent.